WarmlyYours WSHM-240-15064 Installation Manual

WarmlyYours WSHM-240-15064 Installation Manual
Installation Manual for
Slab Heating Systems
24/7 Installation Support • Lifetime Technical Assistance • Free Design Service • www.WarmlyYours.com • (800) 875-5285
CONTENTS
PAGE
1.0 PRODUCT SPECIFICATIONS
1.0 Product Specifications .............................................................................. 1
WarmlyYours Heating Cable is designed for new concrete slab floors. It is well suited
for large areas like basements, garages and additions.
2.0 Selection of the Heating System................................................................. 2
The Heating Cable is comprised of a dual, multistrand heating element with a primary
insulation of Fluoropolymer. The insulated core is then protected with a woven metal
braid and an outer jacket of PVC, EPR or Zero Halogen Polyolefin based compound
to make it sturdier and to provide corrosion protection. These cables are terminated
with 20’ (6.1m) long standard cold leads. The hot and cold junction is uniquely
designed to make it durable and flexible.
3.0 Important Instructions before Installing the System................................... 2
4.0 Installation for Slab Heating........................................................................ 3
4.1 Thermostat & Sensor.......................................................................... 3
4.2 Electrical Provisions for the System.................................................... 3
4.3 Pre-Installation Preparations............................................................... 4
4.4 Installation for Concrete Embedded Applications............................... 4
4.5 Operating Tips..................................................................................... 5
4.6 Installation under Concrete................................................................. 6
4.7 Installation of Slab Heating Mat.......................................................... 6
Available in a wide range of lengths and sizes to suit your requirements, the Slab
Heating Mats and Heating Cables are identified as indicated below.
Item Number: AAAA-BBB-CCCC
Ex: Item Number: WSHM-240-0250
5.0. Testing the Mats and Cable........................................................................ 7
5.1 Test One: Total Cable Resistance........................................................ 7
5.2 Test Two & Three: Insulation Resistance............................................. 7
(product type)
(voltage)
(width & length = 2’x50’)
• A
AAA = WSHM for Slab Heating Mat, WSHC for Slab Heating Cable
• BBB = Operating Voltage available in 120V and 240V
6.0 Warranty...................................................................................................... 7
• C
CCC = Mat width in ft. (first two digits) and Mat length in ft. (third and fourth
digits) for Slab Heating Mat, Cable length in ft. for Slab Heat Cable
7.0 Appendix
Appendix A: Slab Heating Mats................................................................ 8
Appendix B: Slab Heating Cables............................................................. 8
Appendix C: Cross-section of indoor slab Heating Cable in concrete
(With NO floor covering)............................................................................ 9
Appendix D: Cross-section of indoor slab Heating Cable in concrete
(With floor covering).................................................................................. 9
The available lengths of Slab Heating Mats are shown in Appendix A. The available
lengths of Slab Heating Cables are shown in Appendix B. Both Appendices include
the following attributes for each Item Number.
•
•
•
•
•
•
8.0 Troublshooting............................................................................................. 12
9.0 Warranty...................................................................................................... 14
Warranty Registration................................................................................ 15
1
Product Type
Operating Voltage
Cable Length
Mat Width and Length
Total Ohms
Total Watts
• Watts/Ft for Cable or Watts/Sq Ft for Mats
• Amps
10
2.0 SELECTION OF THE HEATING SYSTEM
over cable. Duct tape the ends of shovels. Do NOT saw expansion joints, without
having lines marked off clearly with spray paint, where installer has verified that
Heating Cables will not be cut. Do NOT damage Cables with heavy equipment,
machinery or vehicles.
Selection of your Heating System will depend on the application. The following can
be taken as a general guide:
6. H
eating Cables should be separated from other heat sources such as luminaries,
and fireplaces.
INSTALL CHART
Application
Indoor Slab Heating
Watts per Sq.Ft. (per Sq.M.)
- Cable spacing inches (mm)
Multiplier at
given spacing
20 W/ft2 (161 to 215 W/m2)
Recommended spacing 3” to 3.5” (76
to 89mm).
4 at 3” (76mm)
3.5 at 3.5” (89mm)
3 at 4” (102mm)
2.4 at 5” (127mm)
7. Do not install the Heating Cable below 5˚ F (-15˚ C) ambient temperature.
8. M
inimum bending radius of the Heating Cable shall not be less than 10 times its
diameter.
9. M
inimum spacing of Cables is 3” (76 mm) and maximum spacing of Cables is 5”
(127mm).
10. T
win Conductor Heating Cable has a ground braid (metal sheath) to be connected
to ground and 2 conductors which are to be connected to the power supply.
Formula: Area of Application x Multiplier at given cable spacing = Heated Cable
Length required
Example 1 (English): 100 sq.ft of Slab Heating x 4.0 at 3” spacing = 400 feet of
Heated Cable required
Example 2 (Metric): 9.3 sq.m of Slab Heating x 4.0 at 76mm spacing = 122m of
Heated Cable required
11. D
ouble check the voltage and wattage of the Heating Cable received against
the project specifications on your custom installation plan. These are marked on
the CSA label of the product. A qualified electrician should connect the Heating
System.
12. C
heck the conductor, resistance and insulation resistance of the Heating Cable
before installing and also after installing. Resistance value should match the value
shown in Appendix A and Appendix B. A tolerance of -5% to +10% is allowed.
Insulation resistance must be infinite (500 VDC megger meter required to test).
Note: For normal plain bare slabs, stained or stamped use 3” spacing. For
application when the slab also has a floor covering like tile or wood, use 5” spacing
for a maximum of 15w/sq ft. to meet code requirements.
13. K
eep high voltage power wires in a separate conduit from the low voltage sensor
wire.
14. A
llow sufficient drying or curing period of the slab after installing the Heating
System before energizing the Heating System. (7 day minimum)
Please note the above-indicated values are meant as a general guide. Your values
may vary depending on a number of factors. Please consult your Account Manager
for assistance.
IMPORTANT
2.5”3.0
in (6.3cm)
maximum INSTRUCTIONS
thickness brick or concrete
1. Heating Cable must not cross or
paver
15. F
or easy reference, fix a label at the power distribution board indicating the
location of the heating units installed.
BEFORE INSTALLING THE SYSTEM
WARNING
16. T
he Cable must NOT be shortened or cut in any manner or subjected to strain at
the factory splice joint.
overlap itself at any point. Do not
install cable runs any closer than 3”
1.5”
sand,
stone
on center.
This
could
cause the Cable
dust or mortar
to overheat, requiring replacement.
17. N
EVER power up Heating Cables prior to being buried in concrete, (even for
testing purposes). This will prevent premature failure of the Heating Cable.
2.5” in (6.3cm) maximum
Right
2. T
he Heatingthickness
Cable length
not
brick should
or concrete
be cut or altered
paver under any circumstances. This may cause over heating resulting in
damage to the Cable.
3. A
ll heated portion (blue) and
splice must end up buried completely in the
1.5”factory
sand, stone
concrete. Ensure none of dust
the heated
portion (blue) or the splice (look for heatshrink)
or mortar
8”-12” crushed
enter into any conduit.
Control joint
rock aggregate
4. T
he cold lead can be cut /extended with a conventional splice, inside of an
accessible junction box (weatherproof if outdoors).
hot/cold joints 3
in (7.6 cm) apart
and 6 in (15 cm)
from slab edge
Concrete
tie wrap
5. Take Plastic
precautions
to avoid damage to Heating Cable during installation. Do not drive
8”-12” crushed
rock aggregate
2
Wrong
Wrong
Right
Wrong
hot/cold
cold joints
installed
stalle on
slab edge
hot/cold
cold joints
bunched
unche
hot/cold joints 3
in (7.6 cm) apart
and 6 in (15 cm)
from slab edge
3”
Control joint
3”
Concrete
hot/cold
cold joints
stalle on
installed
slab edge
Wrong
hot/cold
cold joints
unche
bunched
Cold Lead
4.0 INSTALLATION FOR INDOOR SLAB HEATING
WARNING
4.1 TEMPERATURE CONTROLLER & SENSOR
In case the GFCI in our thermostat trips during normal operation, and cannot be
reset, there is likely a fault in the Cable. No attempt should be made to re-energize
the system. The GFCI must not be bypassed under any circumstances. Consult a
qualified electrician.
We recommend a standard Programmable Thermostat with a temperature sensor
specially designed for control of the Heating
System.
120 VAC SUPPLY
1/4” of
(6mm)15 feet (4.5m) in
The sensor normally comes with a 2 SCV-120
conductor lead wire
Twin-conductor
CONTROL
Heating
Cable adjacent runs of
length. Thermostat sensor location shall be centered between two
120
VAC
Heating Cable within metal pipe
or conduit
to allow for replacement. Do not position
RELAY
or
PANEL
240 VAC
Thermostat sensor closer than
1.5 inch (38 mm) to Heating Cable. Sensor cable shall
120 VAC SUPPLY
be routed to the Thermostat located in the wall at suitable operating height. Do not
allow any other Heating Cable to overlap with the sensor cable.
The details of the thermostats and installation guidelines are given
in
SCV-120
CONTROL
MELT MAT
the instruction manual provided with SNOW
the Thermostat.
Length 5’ (152cm) min 50’ (1524cm) max
20’ (610cm)
Cold Lead
2’ (61cm)
or
3’ (91cm)
DIAGRAM A
120V / 240V VAC SUPPLY
Probe type sensor at the
end of 15’ 2 conductor
20AWG wire.
4.2 ELECTRICAL PROVISIONS FOR
THE SYSTEMS
120 VAC
P N E
RELAY
or
The Heating System installation wiring shall be in
with the
National Electric
P Naccordance
E
PANEL
HERMOSTAT
240
VAC
THERMOSTAT
Code and any applicable local codes. Controls
and accessories recommended
for
T-Stat
CONCRETE SLAB
use along with the Heating Cables are listed below:
FLOOR
FLOOR
• Floor Sensing Temperature
controller / Thermostat
SENSOR
3"
(8cm
2-3”
110V / 230V AC SUPPLY
THERMOSTAT
SENSOR WIRE
SENSOR
THERMOSTAT
SENSOR WIRE
SENSOR WIRE
CAPPED
CONDUIT
CAPPED
CONDUIT
FLOOR
HEATING
CABLE
SLAB
4-6”
HEATING
CABLE
HEATING
• Relay Panel(s)
for amp loads greater than
15 amps
SNOW MELT MAT
CABLE
10"
(251mm)
CAPPED 3/4”
METAL CONDUIT
20’ (610cm) Cold Lead
FLOOR
Heating Conductor (Solid/Multistrand)
HEATING
Metal Sheath (Copper/Galvanised Steel/Cladde
CABLE
Primary Insulation (Fluoropolymer)
HEATING SYSTEM
Polyester Sheath
Outer Sheath PVC/Pololefin
• Dedicated Circuit Breaker(s) for all heater circuits. GFCI (5mA trip) or GFPE (30mA
trip) may be required - check local and national code.
SLAB HEATING SYSTEM
OW MELT
MAT zip ties, 2” thick polystyrene insulation (provided SNOW
MELT MAT
• Plastic
by installer)
The location of the Thermostat junction box shall be about 4’ (1.2m) high from the
floor for easy access. The floor sensor wire and the Heating Cable cold leads shall be
routed to the Thermostat / power connection box in separate conduits.
If the Heating System has a load below 1,750W at 120V or 3,500W at 240V based
on thermostat power rating, it may be connected directly to an electronic thermostat
as shown in Diagram A which gives a typical scheme of the electrical system. If the
Heating System has a load more than the thermostat power rating, consult your
WarmlyYours Account Manager. (you’ll likely need a relay panel)
3
4.3 PRE-INSTALLATION PREPARATIONS
1. Review the custom installation plan for the area requiring the Heating System and
verify dimensions listed against your actual field dimensions to ensure they match.
2. Confirm the location of the power supply box/Thermostat and sensor against the
plan.
120 the
VACprocured
SUPPLY
3. Select Heating Cable(s) and ensure that
Cable is correct according to
8. H
eating Cable should be laid so that the Cables are equally spaced. The distance
between two Heating Cable passes should be according to the spacing calculation
determined by WarmlyYours (3” to 5” range).
9. R
oute the power leads through a conduit from the floor to the connection box. If
multiple cables are being used, route all power leads through a conduit from the
floor to the connection box in the wall. Ensure hot section and factory splice do
NOT get into the conduit
the requirements in the following section.
10. Check the resistance and insulation resistance value after laying out Cables.
Check to see if these values are consistent with the pre-install values. Record
4. Check the Slab Heating Cable in the box
visually
and
make
sure
that
it
is
not
1/4” (6mm)
SCV-120
values in the warranty card on page 13.
Twin-conductor
damaged. Check voltage, wattage, resistance
values from the factory test record
CONTROL
20’ (610cm)
Heating
Cable
and verify that they match the required specifications.
11. At this point, the concrete can be poured.
Cold Lead
5. Check resistance 120
of the
conductor and its insulation resistance with a multimeter/
VAC
12. Pour the concrete and spread evenly on the reinforcement mesh / grid. The
megohmmeter as soon
from its packing. Resistance value of
or as it is removed RELAY
concrete floor or slab thickness shall be about 2” (51 mm) on top of the Heating
PANEL
the Heating Cable240
shall
match to the value shown in Appendix A or Appendix B.
VAC
Cable. Typical 4” to 6” slabs will have cable located in middle (2” to 3” from
A tolerance of -5% to +10% is allowed. Insulation resistance should be infinite.
finished surface).
Record it on the warranty card located on page 13 of this manual.
13. Ensure the entire Heating Cable, factory splices and thermostat sensor (in metal
6. The Heating Cable is now ready for installation.
conduit) are embedded in the cement mortar. The choice and application of building
materials should be in accordance with the building material manufacturer’s
instructions. (see diagram B)
4.4 INSTALLATION FOR INDOOR CONCRETE SLAB APPLICATION
1. 2” thick polystyrene insulation (or better) should be installed below slab and around
perimeter edges.
SNOW MELT MAT
2. Reinforcement mesh on the floor or slab should be strong enough to walk on and
not sag or bend.
3. Reinforcement mesh should be properly positioned and supported so that it does
not get disturbed during the concrete pour. Ensure the Heating Cable is on the
reinforcement mesh a minimum of 2” (51mm) below the finished concrete/slab
surface.
14. Ensure the correct curing time for drying of construction materials is followed
before powering ON the Heating Cables (7 day minimum).
15. Check the continuity, resistance and insulation resistance values after the concrete
or mortar is poured. They should be consistent with the values recorded previously.
Record values on the warranty card on page 13 of this manual.
16. Never use 500 VAC megger while personal are standing in, or touching the wet
cement. Wait until personal are out of the wet concrete.
110
P N E
4. Surface preparation of the floor is very important. The floor must be completely free
THERMOSTAT
of all debris including all nails, sharp metallic objects, wood and construction debris.
Make absolutely sure that there are no objects on the floor that might damage the
Heating Cable.
FLOOR
5. Start installing Heating Cable from the location of power connection box.
SENSOR
DIAGRAM B
T-Stat
CONCRETE SLAB
2-3”
SLAB
4-6”
HEATING
CABLE
6. Roll out the Heating Cable. Secure it to the reinforcement mesh or grid using plastic
zip ties (supplied by installer).
7. Heating Cable should be laid 3” (76mm) away from the wall perimeter.
SNOW MELT MAT
4
SENSOR WIRE
SENSOR
CAPPED 3/4”
METAL CONDUIT
H
4a. For Two-Pour Installations: The concrete installer pours the first 2” to 3” (51mm
to 76mm) of concrete. While this first pour is still wet, rebar or wire-mesh should
be placed on top of the first pour. The cables should be attached to the rebar
/ mesh with plastic zip ties, using 3” to 5” (76mm to 127mm) spacing for freeform type cable. At this time, the electrician must route the cold lead(s) thru rigid
metal conduit(s) to get back to an accessible junction box(es). Care must be
taken by the electrician so that none of the heated section nor the factory splice
enters any conduit. This is the best time for sensor placement. Separate conduit
should be used to protect the low voltage sensor wire and must NOT be shared
with any high voltage cold lead from the Heating Cables / Mats. Once conduits
& sensor(s) are placed, the topping pour of concrete can be finished. Again,
the concrete installer(s) must take care not to walk on the hot-cold splice point,
and to avoid damaging the Heating Cables with shovels and rakes. Taping up
the shovel blades helps make them less sharp. It’s recommended that Mats be
placed so the mesh faces up, keeping the wire-side-down to help protect it from
the shovels.
4.5 OPERATING TIPS
1. Energy consumption will vary depending on ambient temperature and building
insulation. For lower energy consumption, use a 7-day Programmable Thermostat
control.
2. Energy consumption can be minimized by turning the system OFF when heating
is not required, but extra time will be required for the floor to warm up once the
system is turned ON again.
3. Avoid placing objects like thick mats, rugs, floor level furniture and mattresses
on the heated floor, especially in the area where the floor temperature sensor is
located. These restrict the transfer of heat away from the Cables and result in the
floor area beneath them being warmer than other areas.
4. Avoid Mats with rubber or vinyl type backing as these may decompose with heat
and could stain flooring.
4.6 INSTALLATION UNDER CONCRETE
4b. F
or Single-Pour Installations: The wire mesh or rebar is first placed by the concrete
installer or electrician. The electrician then must attach the Heating Cable to the
rebar / mesh with plastic zip ties using 3” to 5” (51mm to 127mm) spacing for
free-form type cable. Then the rebar / mesh must be propped up with concrete
rubble, wire chairs, or brick pavers to the appropriate depth so that Heating
Cable / Mat ends up 2” to 3” (51mm to 76mm) from finished surface and no
deeper. Once rebar / mesh / Heating Cable is all propped up, the electrician must
route the cold leads(s) thru rigid metal conduit(s) to get back to an accessible
junction box (es). Care must be taken so that none of heated section or factory
splice enters any conduit. If a slab-mounted sensor will be used, this is the
best time for placement. It should be located in an open area, between 2 runs
of cable. Separate conduit should be used to protect the low voltage sensor
wire and must NOT be shared with any high voltage cold lead from the Heating
Cables / Mats. Once conduits & sensor(s) are placed, the pour of the concrete
can be finished in one step. The concrete installer(s) must take care not to walk
on the hot-cold splice and to avoid damaging the Heating Cables with shovels
and rakes. Mats should be placed mesh facing up, keeping the wire-side-down,
to help protect it from the shovels and rakes.
1. Ensure that the concrete contractor has installed a solid base of 4” to 8” (102 mm
to 203mm) of crushed rock aggregate base and that it is tamped down and ready
for the concrete pour.
2 . It is extremely important that the concrete installer does NOT use any heavy
equipment, machinery, or vehicles over the exposed Heating Cable. During
concrete pours, it is recommended that care be taken to avoid stepping on the
factory splice portion of cable, where the hot section (blue) meets the cold section
(black). This is the location of the factory splice. During this process of installing
the heating product and pouring concrete, it is the responsibility of the electrician
to use a 500 VDC megohmmeter and a multi-meter to keep checking on the
Heating Cables that are currently being worked on top of, to ensure they have not
been damaged, and will be ready for action once the concrete slab has cured.
* Do NOT use 500 VDC megger while personal are still in contact with the wet cement.
3. For installations in basements and warehouses that will include building posts,
it is strongly recommended that the concrete installer pre-sleeve for the posts
to avoid any and all drilling of the concrete. The Heating Cable must be routed
around these sleeves or posts to avoid any direct contact with them. Heating
Cables or Mats must not be allowed to pass thru expansion joint locations. It
is recommended that lines are spray painted on the finished concrete surface
by the electrician to mark off exactly where expansion joints may be located.
It is the responsibility of the electrician and the concrete installer to coordinate
their efforts so they avoid saw-cutting or drilling thru Heating Cables that are no
longer visible beneath the concrete. Following the proposed installation plan from
WarmlyYours will help to ensure this process goes smoothly.
5. The electrician needs to complete final testing of all the Heating Cables / Mats
with a multi-meter and a megohmmeter to verify and record that each Heating
Cable has survived the pour of concrete and is ready for action once the concrete
is cured. (7 day minimum)
5
4.7 INSTALLATION OF SLAB HEATING MAT
Use scissors to cut the Mat. NEVER cut the Heating Cable
For 180 Degree Turn
Turn the Mat
Maintain 3” gap
between all cable
and mat passes
Flip / Turn the
Mat suitably
3”
180˚
For 90 Degree Turn
Maintain 3” gap
between all cable
and mat passes
For other shapes, detach Cable from Mat to required
length and lay only Cable.
Means of attachment may vary
project to project.
3”
Maintain same
spacing 3” to 5”
90˚
Flip the
Mat Reverse
3”
6
Maintain 3”
gap between
all cable and
mat passes
5.0 TESTING THE MATS AND CABLE
In case of defective material, WarmlyYours obligation will be limited to the repair
or supply of new material, free of charge to the customer.
5.1 TEST ONE: TOTAL CABLE RESISTANCE
(MULTI-METER REQUIRED)
The warranty does not cover installations made by unqualified persons or faults
caused by incorrect design by others / misuse / damage caused by others /
damage in transit / incorrect installation and any other subsequent damage that
may occur. Costs related to repair / replacement will be fully chargeable to the
customer if the damage is due to of any of the above reasons.
1. Connect one meter clamp to one cold lead (pigtail) inner conductor and the
other meter clamp to the other cold lead (pigtail) inner conductor.
2. Test in accordance with the meter manufacturer’s instructions and record this
ohm value on the warranty card on last page.
WarmlyYours is under no circumstances liable for consequential damages or
losses including without limitations the loss or profit arising from any cause
whatsoever. The guarantee is a material warranty only and does not cover field
labor.
3. Total nominal cable resistance information is found on the CSA label, the bill of
materials and Appendix A and Appendix B, or can be obtained by calling your
WarmlyYours Account Manager. Actual reading should be within 10% of the
cable resistance.
The warranty is void if there is any payment default and if data is not filled in
attached warranty card.
4. Record measured values on the warranty card on last page. Perform this test
before, during and after installation of the Heating Cables.
TEST #1
5. Please be sure that you write in the full part number of the Cable or Mat next to
your results.
Ohms Test with
Multimeter
5.2 TEST TWO & THREE: INSULATION RESISTANCE
(MEGOHMMETER REQUIRED)
1. Connect one meter clamp to the cold lead (pigtail) inner conductor and the
other meter clamp to the yellow/green (ground) of the Heating Cable.
TEST #2
Insulation Ohms with
500 VDC megger
(Infinite is good value)
Core
Core
Insulation Ohms with
500 VDC megger
(Infinite is good value)
Ground
Ground
2. Test in accordance with the meter manufacturer’s instructions. Recommended
meter is a 500 VDC megohmmeter.
TEST #3
Core
Core
3. Megohmmeter reading should read “infinite”.
4. Record measured values on the warranty card on last page. Perform this test
before, during and after installation of the Heating Cables.
WARNING
5. Duplicate test using inner conductor.
Heating cable may hold a charge after the 500 VDC tests. Allow time for charge to
Black
dissipate before handling the heating cable afterward. Ground
6.0 WARRANTY
WarmlyYours provide a warranty for the Heating Cables for a period of 10 years
from date of purchase, for the material and workmanship under normal operating
conditions.
Black
Ground
Yellow
or Red
7
Yellow
or Red
7.0 APPENDIX A:
WARMLYYOURS SLAB HEATING MATS (SUITABLE FOR CONCRETE)
Part #
Size (ft/m)
Voltage
Area (ft2/m2)
Cable Length (ft/m)
Total Ohms
Total Watts
Watts/ft2 (W/m2)
Amps
WSHM-120-15011
1.5' X 11' (0.46 x 3.35m)
120
16.5 (1.53m2)
57.15 (17.42m)
43.64
330
20 (215W/m2)
2.75
WSHM-120-15016
1.5' X 16' (0.46 x 4.88m)
120
24.0 (2.23m2)
82.22 (25.06m)
30.00
480
20 (215W/m2)
4.00
WSHM-120-15022
1.5' X 22' (0.46 x 6.71m)
120
33.0 (3.07m2)
112.27 (34.22m)
21.82
660
20 (215W/m2)
5.50
WSHM-120-03017
3.0' X 17' (0.91 x 5.18m)
120
51.0 (4.73m2)
172.24 (52.50m)
14.12
1,020
20 (215W/m2)
8.50
WSHM-120-15036
1.5' X 36' (0.46 x 10.97m)
120
54.0 (5.02m2)
182.45 (55.61m)
13.33
1,080
20 (215W/m2)
9.00
WSHM-120-15040
1.5' X 40' (0.46 x 12.19m)
120
60.0 (5.57m2)
202.49 (61.72m)
12.00
1,200
20 (215W/m2)
10.00
WSHM-120-03021
3.0' X 21' (0.91 x 6.40m)
120
63.0 (5.85m2)
212.30 (64.71m)
11.43
1,260
20 (215W/m2)
10.50
WSHM-120-03025
3.0' X 25' (0.91 x 7.62m)
120
75.0 (6.97m )
252.36 (76.92m)
9.60
1,500
20 (215W/m2)
12.50
WSHM-120-15056
1.5' X 56' (0.46 x 17.07m)
120
84.0 (7.80m2)
282.71 (86.17m)
8.57
1,680
20 (215W/m2)
14.00
WSHM-120-03029
3.0' X 29' (0.91 x 8.84m)
120
87.0 (8.09m2)
292.42 (89.13m)
8.28
1,740
20 (215W/m2)
14.50
WSHM-240-15064
1.5' X 64' (0.46 x 19.51m)
240
96.0 (8.92m2)
322.80 (98.39m)
30.00
1,920
20 (215W/m2)
8.00
WSHM-240-15070
1.5' X 70' (0.46 x 21.34m)
240
105.0 (9.75m2)
352.89 (107.56m)
27.43
2,100
20 (215W/m2)
8.75
WSHM-240-03040
3.0' X 40' (0.91 x 12.19m)
240
120.0 (11.15m2)
402.59 (122.71m)
24.00
2,400
20 (215W/m2)
10.00
WSHM-240-15085
1.'5 X 85' (0.46 x 25.91m)
240
127.5 (11.85m2)
428.08 (130.48m)
22.59
2,550
20 (215W/m2)
10.63
WSHM-240-03044
3.0' X 44' (0.91 x 13.41m)
240
132 (12.26m2)
442.65 (134.92m)
21.82
2,640
20 (215W/m2)
11.00
WSHM-240-15095
1.5' X 95' (0.46 x 28.96m)
240
142.5 (13.24m2)
478.22 (145.76m)
20.21
2,850
20 (215W/m2)
11.88
WSHM-240-03048
3.0' x 48' (0.91 x 14.63m)
240
144.0 (13.38m2)
482.71 (147.13m)
20.00
2,880
20 (215W/m2)
12.00
WSHM-240-03052
3.0' x 52' (0.91 x 15.85m)
240
156.0 (14.49m2)
522.77 (159.34m)
18.46
3,120
20 (215W/m2)
13.00
WSHM-240-15112
1.5' X 112' (0.46 x 34.14m)
240
168 (15.61m2)
563.42 (171.73m)
17.14
3,360
20 (215W/m2)
14.00
WSHM-240-03056
3.0' X 56' (0.91 x 17.07m)
240
168.0 (15.61m2)
562.83 (171.55m)
17.14
3,360
20 (215W/m2)
14.00
2
APPENDIX B:
WARMLYYOURS SLAB HEATING CABLES (SUITABLE FOR CONCRETE)
Part #
Voltage
WSHC-120-00057
120
Cable Length
57' (17m)
Total Ohms
Total Watts
Watts/Ft
Amps
43.64
330
5.79 (19W/m)
2.75
WSHC-120-00082
120
82' (25m)
30.00
480
5.85 (19W/m)
4.00
WSHC-120-00112
120
112' (34m)
21.82
660
5.89 (19W/m)
5.50
WSHC-120-00172
120
172' (53m)
14.12
1,020
5.93 (19W/m)
8.50
WSHC-120-00182
120
182' (56m)
13.33
1,080
5.93 (19W/m)
9.00
WSHC-120-00202
120
202' (62m)
12.00
1,200
5.94 (19W/m)
10.00
WSHC-120-00252
120
252' (77m)
9.60
1,500
5.95 (20W/m)
12.50
WSHC-240-00323
240
323' (98m)
30.00
1,920
5.94 (19W/m)
8.00
WSHC-240-00353
240
353' (108m)
27.43
2,100
5.95 (20W/m)
8.75
WSHC-240-00402
240
402' (123m)
24.00
2,400
5.97 (20W/m)
10.00
WSHC-240-00443
240
443' (135m)
21.82
2,640
5.96 (20W/m)
11.00
WSHC-240-00483
240
483' (147m)
20.00
2,880
5.96 (20W/m)
12.00
WSHC-240-00523
240
523' (159m)
18.46
3,120
5.97 (20W/m)
13.00
WSHC-240-00563
240
563' (172m)
17.14
3,360
5.97 (20W/m)
14.00
8
3” (76
m
Spac m)
ing
APPENDIX C:
1.5” to 2” (38mm to 51mm) of base/primer asphalt
4” to 8” (102mm to 203mm) of crushed aggregate
CROSS-SECTION OF INDOOR SLAB HEATING CABLE IN CONCRETE (WITH NO FLOOR COVERING)
3” (76
m
Spac m)
ing
Heating Cable run (tied to the rebar or wire mesh with zip ties)
2” to 3” (51mm to 76mm) of finished concrete
Rebar or wire mesh supported by bricks or metal chairs
Slab heater run
2” to 3” (51mm to 76mm) of concrete
Heating Cable run (tied to the rebar or wire mesh with zip ties)
2” insulation ( polystyrene or better ) must be added on top of
the sand layer, before the base concrete layer.
2” to 3” (51mm to 76mm) of finished concrete
4” thickorsand
crushed
rockby
aggregate
Rebar
wireover
mesh
supported
bricks or metal chairs
3” (76
m
Spac m)
ing
Slab heater run
Conc
rete B
lock o
r Meta
2” to 12”
3” (51mm
to to
76mm)
of concrete
8”
(203mm
305mm)
of crushed rock aggregate base
3” (76
m
Spac m)
ing
l Cha
irs
2” insulation ( polystyrene or better ) must be added on top of
the sand layer, before the base concrete layer.
4” thick sand over crushed rock aggregate
Conc
rete B
8” to 12” (203mm to 305mm) of crushed rock aggregate base
lock o
r Meta
l Cha
irs
APPENDIX D:
Floor Covering
CROSS-SECTION OF INDOOR SLAB HEATING CABLE IN CONCRETE (WITH
FLOOR COVERING)
2” to 3” (51mm to 76mm) of finished concrete
Slab heater run
Rebar or wire mesh supported by bricks or metal chairs
2” to 3” (51mm to 76mm) of base/concrete
Slab heater run
Conc
Floor Covering
2” insulation ( polystyrene or better ) must be added on top of
the sand layer, before the base concrete layer.
2” to 3” (51mm to 76mm) of finished concrete
4” thick sand over crushed rock aggregate
Rebar or wire mesh supported by bricks or metal chairs
8” to 12” (203mm to 305mm) of crushed rock aggregate base
2” to 3” (51mm to 76mm) of base/concrete
5” (12
7m
Spac m)
ing
rete B
lock o
r Meta
2” insulation ( polystyrene or better ) must be added on top of
the sand layer, before the base concrete layer.
l Cha 5” (127m
irs S
m)
pacin
g
4” thick sand over crushed rock aggregate
8” to 12” (203mm to 305mm) of crushed rock aggregate base
Conc
rete B
lock o
r Meta
l Cha
irs
Brick and Stone Pavers must NOT be any thicker
than 2.5” (63.5mm).
1” to 2” (51mm to 76mm) of finished mortar
WHCA heater run
9
Rebar or wire mesh staked to aggregrate base
Brick and Stone Pavers must NOT be any thicker
from slab edge
8”-12” crushed
rock aggregate
APPENDIX
E:
Cold lead is in the conduit
3” gap
astic tie wrap
Thermostat / Relay / or splice box
J
End
4” of cold lead shall be buried
directly in concrete
Factory splice buried in concrete
3” gap
Cold lead is in the conduit
All Blue section of cable on mesh is buried in concrete
Thermostat / Relay / or splice box
J
Conduit
4” of cold lead shall be buried
directly in concrete
Factory splice buried in concrete
All Blue section of cable on mesh is buried in concrete
APPENDIX F:
t
2” to 3” (51mm to 76mm) of finished concrete
Wire mesh with heating cable
2” to 3” (51mm to 76mm) of concrete
2” polystyrene insulation
4” thick sand over crushed rock aggregate
2” to 3” (51mm to 76mm) of finished concrete
8” to 12” (203mm to 305mm) of crushed rock aggregate base
Wire mesh with heating cable
2” to 3” (51mm to 76mm) of concrete
Factory Splice
2” polystyrene insulation
Conduit for heating cable cold lead protrudes into bottom of slab only
10
4” thick sand over crushed rock aggregate
8” to 12” (203mm to 305mm) of crushed rock aggregate base
WIRING DIAGRAM
APPENDIX G:
For 120V & 240V Slab Heating Products with
SLAB HEATING DIAGRAM: 240V - TYPICAL LINE DIAGRAM (FOR 6 CIRCUITS/CABLES)
WITH
THERMOSTAT
CONTROL
nSpire
Touch
Wi-Fi (UWG4),
nSpire Touch (UDG4),
nHance (UDG), nTrust (UTN4), nJoin (USG)
CUITS
120/240V
120/240 VAC
BREAKER PANEL
120V/240V
THERMOSTAT
15 AMPS MAX
V CIR
0/240
12
120/240V CIRCUITS
J-BOX
RED 240V
or
YELLOW 120V
L2(N)
LINE
ABCD
HOT (240V) or
NEUTRAL (120V)
HOT
MATS OR CABLES THAT
TOTAL LESS THAN 15 AMPS
FRONT OF THE BASE
out
3
ENSURE THE SYSTEM
IS GROUNDED
FLOOR SENSOR
120/240VAC
in / sensorr
1
1800W/3600W MAX 15A
SLAB TEMP SENSOR PROBE TO BE
ENCLOSED IN METAL CONDUIT THAT IS
CAPPED OFF, BETWEEN TWO PASSES OF
HEAT CABLE.
HOUSE GROUND
FLOOR
LOAD
HEATER MAT/CABLE
LOW VOLTAGE
REAR OF THE BASE
4
HEATER MAT/CABLE
HEATER MAT/CABLE
HEATER CABLE PIGTAIL COLD LEADS TO BE TAKEN
THROUGH 3/4” (19MM) RIGID METAL CONDUIT, OR
OTHER APPROVED MEANS, BACK TO J-BOXES.
TO HEATING PRODUCT
Installation Support • No Nonsense™ Warranty • (800) 875-5285 • www.WarmlyYours.com
(CONDUIT SIZE AS PER INSTALLER)
1. MAT/CABLE HAS NO POLARITY
2. DO NOT CUT THE HEATING WIRE
3. ALWAYS TEST OHMS OF HEATING
PRODUCT BEFORE, DURING AND AFTER
INSTALLATION
4. ALWAYS TEST SENSOR AND VERIFY
8-15 K OHM RESISTANCE
5. NEVER INSTALL ELECTRIC FLOOR
HEATING UNDER PERMANENT FIXTURES
6. THE INSTALLATION MUST COMPLY WITH ALL
NATIONAL AND LOCAL ELECTRICAL AND
BUILDING CODES, INCLUDING AUTHORITY
HAVING JURISDICTION.
SLAB TEMP SENSOR PROBE TO BE
ENCLOSED IN METAL CONDUIT THAT IS
CAPPED OFF, BETWEEN TWO PASSES OF
HEAT CABLE.
C
US
LISTED
Installation Support • (800) 875-5285 • www.WarmlyYours.com
11
Slab Heat Troubleshooting Guide
SYSTEM NOT WARMING
NO POWER TO HEATING PRODUCT
1. Do an amp draw test on the cables to verify proper operation.
1. T
est ohms of heating cables/rolls
2. Thermostat/control set at too low of a temperature. Adjust to higher temperature.
Because of the nature of slab heat, any changes in slab temperature will take time to
accomplish. Slab heat has a much slower reaction time that floor surface heating.
a. V
erify proper ohms per roll/cable
b. Verify no shorts
c. V
erify no open circuits
3. Severe Weather.
2. Inspect breaker/reset
a. Extreme outdoor conditions may affect slab temperature. Depending on the
insulation values under the slab and around the perimeter of the slab, extreme
outdoor temperatures can adversely affect the final temperature of the slab.
a. Verify proper operation
b. Verify proper amperage rating per install plan. Recalculate amp load.
c. Verify proper mA rating of breaker
4. Insufficient watt density. Verify spacing of product vs the design plan.
d. Replace defective breaker
a. The more distance between the heating wire, the lower the watts per square foot.
The lower the watts per foot, the less satisfactory the performance. This type
of system will have to run longer amounts of time, and may not reach desired
temperature.
e. Verify use of dual pole breakers for 240V heaters
3. Inspect Relay panel (if present)
a. Inspect/replace any faulty wiring
b. Inspect/redo/replace any faulty wiring terminals
5. Wrong voltage is being supplied to heating cable.
c. Inspect/replace relay
a. Is 120V being supplied to a 240V cable?
d. Verify proper trigger voltage entering relay panel/trigger relay
b. Is the installed product drawing the correct number of amps?
4. Inoperative Thermostat
6. Test ohms of heating product
a. Verify proper connections and power to controller
a. Verify proper ohms per roll/cable
b. Verify proper voltage to controller
b. Verify no shorts or open circuits
c. Verify voltage going into controller equals voltage exiting controller
7. Inspect breaker/reset
d. Verify voltage of heating product matches that supplied to controller.
8. Inspect wiring and connections inside any junction boxes
e. Verify proper setup/programming of controller
9. Test ohms of sensor. Call WarmlyYours to verify value.
f. Test/inspect sensor/s for proper operation (see troubleshooting guide for controller)
g. Replace defective controller or sensor
5. Wrong voltage is being supplied to heating cable.
a. Has 240V been supplied to a 120V product? If so, test ohms of heating product.
b. Do the ohms match the data sheet for installed product?
c. Repair/replace damaged heating product.
6. Inspect wiring between breaker box and control, between control and sensor/s,
control and relay panel (if present), and between relay panel and any
junction box/es.
7. Inspect heater connections inside all junction boxes.
12
Slab Heat Troubleshooting Guide
MEGA-OHM INSULATION READINGS LOWER THAN SPEC
c. Use troubleshooting kit and thermal camera to locate damage
d. Repair damaged area of lead
e. Replace damaged heating product
1. Rain or high humidity present
a. Dry wires at test point
b. Check for water ingress at junction boxes
c. Dry connections and re-test.
2. Physical damage to cold lead, splice, or heating product
a. Inspect installation area. Has any work been done in area by trade personnel? Is
there visible damage to the concrete slab?
b. Use troubleshooting kit and thermal camera to locate damage
c. Repair damaged area of cable
d. Replace damaged heating product
HEATING PRODUCT RESISTANCE INFINITE
1. Open circuit
a. U
se troubleshooting kit (from conductor to conductor) and thermal camera to
locate fault
b. Repair damaged area of heating product
HEATING PRODUCT RESISTANCE ZERO
HEATING PRODUCT RESISTANCE LOWER THAN SPECIFICATION
1. Conductor shorted to ground somewhere in heating cable
a. Test for ohms across conductors to ground and compare to spec for that product
b. U
se troubleshooting kit (from conductor to ground) and thermal camera to locate fault
c. Repair damaged area of heating product
2. Both conductors shorted together somewhere in heating cable
a. Test for ohms across conductors and compare to spec for that product
b. U
se troubleshooting kit (from conductor to conductor) and thermal camera to
locate fault
c. Repair damaged area of heating product
HEATING PRODUCT RESISTANCE HIGHER THAN SPECIFICATION
1. Conductor shorted to ground somewhere in heating cable
a. T
est for ohms across conductors to ground and compare to spec for that product
b. U
se troubleshooting kit (from conductor to ground) and thermal camera to locate
fault
c. Repair damaged area of heating product
2. Both conductors shorted together somewhere in heating cable
a. Test for ohms across conductors and compare to spec for that product
b. U
se troubleshooting kit (from conductor to conductor) and thermal camera to
locate fault
c. Repair damaged area of heating product
3. Cold lead damaged
a. Inspect exposed coldlead
b. Inspect installation area. Has any work been done in area by trade personnel?
Is there visible damage to the concrete, slab, or pavers?
1. Conductor/s shorted to ground at factory splice
a. Use troubleshooting kit and thermal camera to locate fault
b. Remove factory splice and repair damaged area of heating product
c. C
ontact WarmlyYours for instructions on returning Factory Splice for inspection
RESETTING CIRCUIT BREAKER
1.Test ohms of heating cables/rolls
a. Verify proper ohms per roll/cable
b. Verify no shorts
c. Verify no open circuits
d. Use troubleshooting kit and camera to locate fault
e. Repair fault
2.Inspect breaker/reset
a. Verify proper operation
b. Verify proper amperage rating per install plan (re-calculate circuit load)
c. Verify proper mA rating of breaker (30 mA GFEP breaker required by code)
d. Replace defective breaker
e. Verify use of dual pole breakers for 208 & 240V heaters
3.Inspect all connections
a. Correct any incorrect wiring at all connections in the power feed
4.Inspect Junction Box/es
a. Install drains in boxes if required
b. Dry connections and re-connect
c. Replace any faulty junction boxes
13
WarmlyYours Slab Heating Warranty
WarmlyYours, Inc. warrants the WarmlyYours slab heating cables and mats (“the Product”) to be free from defects in materials and workmanship for ten
years from the date of purchase, provided that the Product is installed in accordance with the WarmlyYours product installation guide, any special written
or oral design or installation guidelines provided by WarmlyYours for the specific project that the Product is intended, the provisions of the National Electric
Code (NEC), and all applicable local building and electrical codes. If the Product is determined to be defective in materials and workmanship, and has not
been damaged as a result of misuse, misapplication or improper installation, WarmlyYours will replace the Product or refund the original cost of the Product.
Controls sold under the WarmlyYours name are warranted for two years from date of purchase. Should the control be defective or malfunction, return the
control to WarmlyYours and it will be repaired or replaced (at WarmlyYours’ option). The warranty does not cover removal or reinstallation costs. See entire
warranty in packaging. Other controls carry their manufacturer’s warranty.
WarmlyYours Inc. assumes no responsibility under this warranty for any damage to the Product prior to or during installation by anyone, including, but not
limited to trades people or visitors to the job site, or damage caused as a result of post installation work. Call our toll free number, (800) 875-5285, if you
have any questions about installation. The Limited Warranty is null and void if the Product owner or his representative attempts to repair the Product without
receiving authorization. Upon notification of an actual or possible problem, WarmlyYours will issue an Authorization to Proceed under the terms of the Limited
Warranty. WarmlyYours reseves the right to void said warranty, if the product owner repairs any heating wire, for any reason.
Warranty Subject to the Following Conditions: 1. The warranty of the slab heating system must be registered by completing and returning the attached
‘WarmlyYours Warranty Registration’ card to WarmlyYours, Inc. within thirty days of date of purchase. Please keep your invoice, as proof of date of purchase
will be required in the event of a claim. 2. The slab heating cables or mats must be installed properly under concrete, asphalt or in mortar under pavers 3.
The slab heating system must be electrically grounded and protected by a GFI (Ground Fault Interrupter). 4. The installation must comply with all national
and local electrical and building codes, as well as any other applicable statutory requirements. 5. The manufacturer hereby reserves the right to inspect the
installation site at any reasonable time. 6. The warranty is not automatically transferred with change of ownership, but the manufacturer may, on application,
transfer the warranty for the period remaining. This transfer is solely at the discretion of the manufacturer. 7. The slab heating system should be used strictly
in accordance with the following: 7a. Hard wire the slab heating cables and mats to a dedicated circuit. The voltage of the circuit should match the voltage
of the slab heating system, and the size of the circuit should be such that the system does not occupy more than 80% of the circuit capacity. 7b. Should you
feel no warmth from the surface that the system is installed within 60 minutes, verify that there is power to the control or thermostat. Contact WarmlyYours
after verifying that there is power to the system. Under no circumstances should you or anyone else tamper with or attempt to repair the snow melt or slab
heating system - this will render the warranty null and void. 7c. Switch the system on and off as you would any conventional electric heater, although timers
or thermostats may be used if preferred. 7d. Use reasonable care in the operation of the system. Do not drop heavy articles, pierce or cut the surface that
the heating system is installed. 7e. All restrictions and warnings detailed in the installation guide must be strictly followed.
WARMLYYOURS, INC. DISCLAIMS ANY WARRANTY NOT PROVIDED HEREIN, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. WARMLYYOURS FURTHER DISCLAIMS ANY RESPONSIBILITY FOR SPECIAL,
INDIRECT, SECONDARY, INCIDENTAL, OR CONSEQUENTIAL DAMAGES ARISING FROM OWNERSHIP OR USE OF THIS PRODUCT, INCLUDING
INCONVENIENCE OR LOSS OF USE. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE OF THIS DOCUMENT. NO AGENT
OR REPRESENTATIVE OF WARMLYYOURS HAS ANY AUTHORITY TO EXTEND OR MODIFY THIS WARRANTY UNLESS SUCH EXTENSION OR
MODIFICATION IS MADE IN WRITING BY A CORPORATE OFFICER.
WarmlyYours Slab Heat Warranty Registration
Thank you for purchasing your new WarmlyYours Slab Heating System. Once the report form is completed, please copy the form and attach a copy to the main breaker box, or
give to the homeowner or business owner. Please send a copy to WarmlyYours via mail, FAX at (800) 408-1100, or scan and send via e-mail to: [email protected]
HOMEOWNER/JOB LOCATION INFORMATION
Name
Phone
Address
Email
City
State
Order Number
Job Name
ZIP
ELECTRICIAN INFORMATION
PAVING/CONCRETE INSTALLER INFORMATION
Company Name
Company Name
Address
Address
City
State
Installer Name
Phone
Install Date:
ZIP
City
State
Installer Name
Phone
ZIP
Installed Under: q Concrete q Asphalt q Pavers q Other If Pavers, thickness of the Paver:___________________ [2.5” (64mm) Max]
Material Depth Below Cable [2” (51mm) Min.]:
Cable/Mat 1
Material Depth Above Cable [1.5” (38mm) Min.]:
Cable/Mat 2
Cable/Mat 3
Cable/Mat 4
Cable/Mat 5
Cable/Mat 6
Zone ID
OHM Reading 1 - Before Install
*MegOHM Reading 1 - Before Install
OHM Reading 2 - During Install
*MegOHM Reading 2 - During Install
OHM Reading 3 - After Install
*MegOHM Reading 3 - After Install
PART #
Serial Number - Internal Use Only
QC MEGOHM - Internal Use Only
QC OHM - Internal Use Only
Megohms readings are done across the assembly’s green, ground wire to each conductor separately. Remember to keep a copy of this form with your warranty.
*If at any time a value does not read infinite, please halt installation and contact WarmlyYours at (800) 875-5285.
Installation Support • (800) 875-5285 • www.WarmlyYours.com
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